Polymeric Insert for Electrical Control Module Fastener Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of electrical control modules is costly and time-consuming due to the management and installation of multiple machine screw fasteners, lock washers, and nuts used to attach electrical components.
Innovation Solution
A polymeric insert is used to physically assemble electrical components within the module, eliminating the need for separate fasteners by relying on the fasteners used to assemble the housing, with features like spring elements and guide surfaces for secure and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple machine screw fasteners, lock washers, and nuts are used to attach electrical components to a mounting plate, then the physical connection is robust and flexible, but the assembly cost and time increase significantly
Solution Approach 1:
The patent combines the mounting plate and electrical component housing into a single integrated housing structure. The housing serves dual functions as both the enclosure and the mounting surface for electrical components, eliminating the need for separate mounting plates and multiple fasteners. This merging reduces assembly complexity and time while maintaining structural integrity.
Solution Approach 2:
The housing is designed to serve multiple functions: it provides mechanical protection for internal components, serves as the structural enclosure, and acts as the mounting surface for electrical components. This multi-functionality eliminates the need for separate dedicated mounting plates, reducing the number of fasteners required while maintaining robust connections.
2Strength
If multiple machine screw fasteners, lock washers, and nuts are used to attach electrical components, then the connection is physically robust, but the device complexity increases
Solution Approach 1:
The patent merges the mounting plate function into the housing structure itself. The housing includes integrated mounting surfaces and attachment features that directly secure electrical components without requiring separate mounting plates, fasteners, lock washers, and nuts. This reduces device complexity while maintaining connection strength.
Solution Approach 2:
The housing is designed as a multi-functional component that simultaneously provides structural support, mechanical protection, and mounting capabilities. By making the housing universal for both enclosure and mounting purposes, the patent eliminates the need for multiple specialized components, thereby reducing overall device complexity.
3Productivity
If a polymeric insert with spring elements is used to assemble electrical components, then assembly time is reduced and complexity is simplified, but the question arises whether separate fasteners are needed to secure the insert to the housing
Solution Approach 1:
The patent integrates the polymeric insert directly into the housing structure through molded-in attachment features. The insert includes integrally formed attachment means that mechanically bond with corresponding features in the housing during the molding process, eliminating the need for separate fasteners to secure the insert. This merging of the insert and housing reduces fastener management complexity while maintaining high assembly productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces assembly time and complexity, enhances rigidity, and prevents lateral motion of components, while providing a robust and flexible method for attaching various electrical components without the need for screws, thus simplifying the assembly process and reducing the risk of incorrectly installed components.
Implementation Method 1
A polymeric insert is within the contained volume and provides mounting surfaces for electrical components... The spring elements may be cantilevered polymeric beams deflected by the compression surfaces... to compress the same and secure the polymeric insert within the housing
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An electrical control module provides a plastic insert fitting inside a housing and compressed by assembly of the housing lid and base to be held securely therein. Elastic components on the plastic insert are compressed during the assembly provide a secure retention in the face of normal manufacturing tolerances. The plastic insert includes features for attaching electrical components such as electrical contactors, motor starters, disconnect switches, circuit breakers, and overload switches without conventional screw fasteners or the like through channels and elastic detents.